Erratic Engine Speed Control at Closed Throttle - Elevated Engine RPM, Crank/No Start and/or Stall (Verify Engine Control Module (ECM) Calibration, Reprogram ECM, if Necessary)

This bulletin includes a revised service procedure with new calibrations. Please discard Corporate Bulletin Number 04-06-04-029 (Section 06 -- Engine/Propulsion System).

Some customers may comment on erratic engine performance at idle (closed throttle). One or more of the following conditions may be observed:

Previous ECM software may not track IAC valve position accurately.

Verify current ECM calibration and reprogram ECM using Saturn Service Stall System version TIS 8.0 2004 or later data CD, if necessary. Refer to service procedure in this bulletin.

1. With engine running at idle speed, monitor "IAC Position" using Tech 2 scan tool. Acceptable normal range at operating temperature with A/C OFF is 25-85 counts.
2. If IAC Position counts are out of the expected range and/or swing erratically, verify engine calibration and reprogram ECM if necessary. Refer to "Verifying Calibration ID Number" and "Reprogramming ECM" procedures in this bulletin.
3. If engine idle speed remains erratic after ECM reprogramming, refer to "Rough, Unstable, or Incorrect Idle and Stalling" diagnostic procedure in the Engine section of the 2003 or 2004 Saturn ION Service Manual, Vol. 1 (SI Document ID #1233175 [for both 2003 and 2004 model year vehicles]).

Verifying Calibration ID Number

Important: You must view calibration numbers using the Tech 2 Scan Tool and NOT the Saturn Service Stall System (SSS).

1. Connect Scan Tool to the vehicle.
2. Navigate to the 2.2L (VIN F) Powertrain Menu.
3. Select ID INFORMATION.
4. Select ENGINE INFORMATION.
5. Read CALIBRATION ID.

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If the current ECM calibration ID is the same or later than the calibration listed in the appropriate model year "Calibration Information Table," do not reprogram the ECM. The updated calibration is already installed and reprogramming is not required. Refer to "Rough, Unstable, or Incorrect Idle and Stalling" diagnostic procedure in the Engine section of the 2003 or 2004 Saturn ION Service Manual, Vol. 1 (SI Document ID #1233175 [for both 2003 and 2004 model year vehicles]) to diagnose condition.

•	If calibration ID number is not the same or later than the calibration listed in the appropriate model year "Calibration Information Table," then reprogram ECM with latest available service calibration. Refer to "Reprogramming ECM" procedure in this bulletin.

Reprogramming ECM

Important: Before installing new ECM calibration, make sure the Saturn Service Stall System (SSS) version is TIS 8.0 2004 or later.

Important: While ignition is OFF, apply parking brake to disable daytime running lights (DRLs) prior to starting reprogramming procedure.

Important: Technician must select "Replace and Reprogram" option in order to reprogram the ECM.

Reprogram the ECM with the appropriate updated calibration listed in this bulletin. Refer to the "Calibration Information Table" to select the correct calibration for the vehicle being serviced. (If newer calibrations than those listed in the "Calibration Information Table" are available, install the latest available service calibration.) Use Saturn Service Stall System (SSS) software version TIS 8.0 2004 or later data CD. Refer to "Service Programming System (SPS)" in the SSS User Guide and "Service Programming System (SPS)" in the Vehicle Control Systems section of the 2003 or 2004 Saturn ION Service Manual, Vol. 3, for reprogramming procedures.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for J6354 (ECM/PCM - Install New Calibration).